Adjustable-height inserts and related methods

Abstract

A two-part adjustable-height insert may be installed in a bore of a sandwich panel, such that the adjustable-height insert may be configured to transfer a load to the sandwich panel. The adjustable-height insert may include a first insert part and a second insert part that may be selectively operatively positioned with respect to each other. The adjustable-height insert may be configured such that an interference fit between the first insert part and the second insert part may be engaged by moving a second flange of the second insert part towards a first flange of the first insert part, which may thereby reduce the overall height of the adjustable-height insert to a selected height. Presently disclosed adjustable-height inserts may be configured for flush installation in a sandwich panel. Methods of installing such adjustable-height inserts and adjusting the height of the same are also disclosed.

The invention claimed is: 
     
       1. An adjustable-height insert, comprising:
 a first insert part comprising:
 a first flange having a first upper surface and a first lower surface; 
 a first neck extending from the first upper surface of the first flange; and 
 a first hole extending at least through the first neck and defined at least partially by a first inner surface of the first neck, wherein the first neck comprises a first outer surface opposite the first inner surface; and 
 
 a second insert part comprising:
 a second flange having a second upper surface and a second lower surface; 
 a second neck extending from the second lower surface of the second flange; 
 a second hole extending through the second neck and the second flange, wherein the second hole is partially defined by a second inner surface of the second neck; and 
 a plurality of radially-extending projections extending from the second flange, adjacent the second upper surface of the second flange, wherein the plurality of radially-extending projections are spaced apart about a peripheral edge of the second flange, and wherein at least some of the plurality of radially-extending projections extend along less than half of a height of the second flange, 
 
 wherein the second insert part is configured to be selectively operatively positioned with respect to the first insert part such that the second inner surface of the second neck engages the first outer surface of the first neck with an interference fit, wherein the adjustable-height insert is configured to have a selectively adjustable overall height such that moving the second insert part with respect to the first insert part such that the second flange is moved towards the first flange reduces the overall height of the adjustable-height insert, wherein the overall height of the adjustable-height insert is defined as the perpendicular distance between the second upper surface of the second flange and the first lower surface of the first flange, and wherein the first hole and the second hole are at least substantially concentric when the second insert part is operatively positioned with respect to the first insert part. 
 
     
     
       2. The adjustable-height insert according to  claim 1 , wherein the adjustable-height insert is configured to be installed within a bore of a sandwich panel, and wherein the adjustable-height insert further comprises an anti-rotation feature configured to resist rotation of the adjustable-height insert with respect to the sandwich panel once the adjustable-height insert is installed in the bore of the sandwich panel and a potting compound is injected into the bore. 
     
     
       3. The adjustable-height insert according to  claim 2 , wherein the anti-rotation feature comprises a textured surface and wherein the textured surface forms at least a portion of the second neck of the second insert part. 
     
     
       4. The adjustable-height insert according to  claim 1 , wherein the first hole extends through the first flange. 
     
     
       5. The adjustable-height insert according to  claim 1 , wherein each respective radially-extending projection of the plurality of radially-extending projections has a respective maximum width and a respective height, and wherein at least some of the plurality of radially-extending projections have a respective maximum width that is greater than the respective height of the respective radially-extending projection. 
     
     
       6. The adjustable-height insert according to  claim 1 , wherein the adjustable-height insert is configured to be installed in a bore of a sandwich panel, the sandwich panel comprising a first skin, a second skin opposite the first skin, and a core therebetween, and wherein the adjustable-height insert is configured such that the plurality of radially-extending projections engage one of the first skin and the second skin of the sandwich panel when the second insert part is operatively positioned with respect to the first insert part and the adjustable-height insert is installed in the bore of the sandwich panel. 
     
     
       7. The adjustable-height insert according to  claim 6 , wherein the adjustable-height insert is configured such that the second upper surface of the second flange is at least substantially flush with one of the first skin and the second skin of the sandwich panel when the second insert part is operatively positioned with respect to the first insert part and the adjustable-height insert is installed in the bore of the sandwich panel. 
     
     
       8. The adjustable-height insert according to  claim 6 , wherein the plurality of radially-extending projections are configured to prevent the second upper surface of the second flange from being positioned sub-flush with respect to one of the first skin and the second skin of the sandwich panel when the second insert part is operatively positioned with respect to the first insert part and the adjustable-height insert is installed in the bore of the sandwich panel. 
     
     
       9. The adjustable-height insert according to  claim 1 , wherein the second flange is tapered such that a first diameter of the second flange adjacent the second upper surface is greater than a second diameter of the second flange adjacent the second lower surface. 
     
     
       10. The adjustable-height insert according to  claim 9 , wherein the first diameter of the second flange, adjacent the second upper surface, is slightly smaller than a bore diameter of a bore in a sandwich panel in which the adjustable-height insert is configured to be installed. 
     
     
       11. The adjustable-height insert according to  claim 1 , wherein each radially-extending projection of the plurality of radially-extending projections comprises a top projecting surface and an angled surface, wherein the top projecting surface is at least substantially parallel to the second upper surface of the second flange, wherein the top projecting surface forms a projection angle with the angled surface, and wherein the projection angle is acute. 
     
     
       12. The adjustable-height insert according to  claim 1 , wherein the adjustable-height insert is configured such that the overall height of the adjustable-height insert is adjustable once the first insert part and the second insert part are at least partially inserted into a bore of a sandwich panel. 
     
     
       13. A sandwich panel, comprising:
 a first skin having a first inner surface and a first outer surface opposite the first inner surface; 
 a second skin opposite the first skin, the second skin having a second inner surface and a second outer surface opposite the second inner surface, and the first outer surface and the second outer surface facing away from one another; 
 a core sandwiched between the first inner surface of the first skin and the second inner surface of the second skin; 
 at least one bore formed in at least one of the first skin and the second skin, and extending into the core; and 
 at least one adjustable-height insert according to  claim 1 , each adjustable-height insert of the at least one adjustable-height inserts being installed in a respective bore of the sandwich panel. 
 
     
     
       14. A method of installing an adjustable-height insert into a bore formed in a sandwich panel, the method comprising:
 installing an adjustable-height insert into the bore, wherein the adjustable-height insert comprises:
 a first insert part comprising:
 a first flange having a first upper surface and a first lower surface; 
 a first neck extending from the first upper surface of the first flange; and 
 a first hole extending at least through the first neck and defined at least partially by a first inner surface of the first neck, wherein the first neck comprises a first outer surface opposite the first inner surface; and 
 
 a second insert part comprising:
 a second flange having a second upper surface and a second lower surface; and 
 a second neck extending from the second lower surface of the second flange; 
 a second hole extending through the second neck and the second flange, wherein the second hole is partially defined by a second inner surface of the second neck; and 
 a plurality of radially-extending projections extending from the second flange, adjacent the second upper surface of the second flange, wherein the plurality of radially-extending projections are spaced apart about a peripheral edge of the second flange, and wherein at least some of the plurality of radially-extending projections extend along less than half of a height of the second flange, wherein the second insert part is configured to be selectively operatively positioned with respect to the first insert part such that the second inner surface of the second neck engages the first outer surface of the first neck with an interference fit, wherein the adjustable-height insert is installed into the bore such that at least a portion of the first neck and at least a portion of the second neck of the adjustable-height insert are positioned within the bore of the sandwich panel; and 
 
 
 adjusting a height of the adjustable-height insert until the plurality of radially-extending projections of the adjustable-height insert engage the sandwich panel and the second upper surface of the second flange is at least substantially flush with an outer surface of the sandwich panel. 
 
     
     
       15. The method according to  claim 14 , further comprising forming a plurality of bores in the sandwich panel, the sandwich panel having a first skin having a first inner surface and an opposite first outer surface, a second skin opposite the first skin, the second skin having a second inner surface and an opposite second outer surface, the first outer surface and the second outer surface facing away from one another, and a core sandwiched between the first inner surface of the first skin and the second inner surface of the second skin, wherein the forming the plurality of bores comprises forming the plurality of bores such that they extend through at least one of the first skin and the second skin and into the core, and wherein the installing the at least one adjustable-height insert comprises installing a plurality of adjustable-height inserts, each respective adjustable-height insert of the plurality of adjustable-height inserts being installed into a respective bore of the plurality of bores. 
     
     
       16. The method according to  claim 14 , wherein the installing the adjustable-height insert into the bore comprises positioning the first flange adjacent a second skin of the sandwich panel, such that the first neck extends into the bore towards a first skin of the sandwich panel, and positioning the second insert part such that the second neck is positioned between the first flange of the first insert part and the second flange of the second insert part. 
     
     
       17. The method according to  claim 14 , wherein the installing the adjustable-height insert into the bore comprises first inserting the first insert part into the bore and then inserting the second insert part into the bore such that the second inner surface of the second neck is at least partially positioned on the first outer surface of the first neck and such that the first hole and the second hole are substantially concentric. 
     
     
       18. The method according to  claim 14 , wherein the adjusting the height of the adjustable-height insert comprises adjusting the height of the adjustable-height insert until the plurality of radially-extending projections are pressed into one of a first skin and a second skin of the sandwich panel. 
     
     
       19. The method according to  claim 14 , wherein the adjusting the height of the adjustable-height insert comprises moving the second flange with respect to and towards the first flange and engaging an interference fit between the first neck and the second neck. 
     
     
       20. A system, comprising:
 a plurality of first adjustable-height inserts; and 
 a plurality of second adjustable-height inserts, wherein each second adjustable-height insert of the plurality of second adjustable-height inserts and each first adjustable-height insert of the plurality of first adjustable-height inserts comprises:
 a first insert part comprising:
 a first flange having a first upper surface and a first lower surface; 
 a first neck extending from the first upper surface of the first flange; and 
 a first hole extending at least through the first neck and defined at least partially by a first inner surface of the first neck, wherein the first neck comprises a first outer surface opposite the first inner surface; and 
 
 a second insert part comprising:
 a second flange having a second upper surface and a second lower surface; and 
 a second neck extending from the second lower surface of the second flange; 
 a second hole extending through the second neck and the second flange, wherein the second hole is partially defined by a second inner surface of the second neck; and 
 a plurality of radially-extending projections extending from the second flange, adjacent the second upper surface of the second flange, wherein the plurality of radially-extending projections are spaced apart about a peripheral edge of the second flange, and wherein at least some of the plurality of radially-extending projections extend along less than half of a height of the second flange, and wherein the second insert part is configured to be positioned on the first insert part such that the second inner surface of the second neck engages the first outer surface of the first neck with an interference fit, 
 
 
 wherein each respective first adjustable-height insert has a first minimum overall height and a first maximum overall height when the respective second insert part is operatively positioned with respect to the respective first insert part of each respective first adjustable-height insert, and 
 wherein each respective second adjustable-height insert has a second minimum overall height and a second maximum overall height when the respective second insert part is operatively positioned with respect to the respective first insert part of each respective second adjustable-height insert, wherein the second minimum overall height of each second adjustable-height insert is greater than the first minimum overall height of each first adjustable-height insert, and wherein the second maximum overall height of each second adjustable-height insert is greater than the first maximum overall height of each first adjustable-height insert.